supercritical carbon dioxide power cycle development...
TRANSCRIPT
Page 1 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
The 4th International Symposium – Supercritical CO2 Power Cycles
Technologies for Transformational Energy Conversion
September 9-10, 2014, Pittsburgh, Pennsylvania
Supercritical Carbon Dioxide Power Cycle Development Overview
Kenneth J Kimball
BMPC, Knolls Atomic Power Laboratory
P.O. Box 1072, Schenectady, NY 12301-1072
Ken Kimball has been actively involved with supercritical CO2 Brayton power cycle development since 2005 working at the Knolls Atomic Power Laboratory in Schenectady, NY, USA. This effort has included working closely with numerous University, National Laboratory and Industry groups. He has a BS degree in mechanical engineering from Worcester Polytechnic Institute and an MS degree in mechanical engineering from Rensselaer Polytechnic Institute. He has previously presented development progress at the Supercritical CO2 Brayton power cycle development symposiums in 2009 and 2011 and the ASME Turbo Conferences in 2012 and 2013.
Page 2 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Abstract
Bechtel Marine Propulsion Corporation (BMPC) is testing a supercritical carbon
dioxide (S-CO2) Brayton system at the Bettis Atomic Power Laboratory. The 100
kWe Integrated System Test (IST) is a two shaft recuperated closed Brayton cycle
with a variable speed turbine driven compressor and a constant speed turbine
driven generator using S-CO2 as the working fluid. The IST was designed to
demonstrate operational, control and performance characteristics of an S-CO2
Brayton power cycle over a wide range of conditions. The IST design includes a
comprehensive instrumentation and control system to facilitate precise control of
loop operations and to allow detailed evaluation of component and system
performance. A detailed dynamic performance model is being used to predict IST
performance, support test procedure development and to evaluate test results.
An overview of IST testing progress and plans is provided. Testing in the IST was
initiated in 2012. Test operations to date included successful system startup, initial
transition to electrical power generation, increased power operations and transition
to load control testing using independent speed control of the turbo-machinery.
Results of testing completed to date and future testing plans will be summarized.
Page 3 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Supercritical Carbon Dioxide Power Cycle Development Overview
September 10, 2014
KJ Kimball Bechtel Marine Propulsion Corporation
Bechtel Marine Propulsion Corporation Knolls Atomic Power Laboratory Schenectady, NY Bettis Atomic Power Laboratory West Mifflin, PA
Page 4 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
BMPC Development Program Overview:
– S-CO2 Brayton Cycle Integrated Systems Test (IST)
• Turbo-machinery (turbine, compressor, bearings, seals)
• Control system (startup, power control)
• Heat exchangers (shell and tube)
• Practical considerations (mass control, instrumentation,
system leakage)
– Compact Heat Exchanger Development
• High pressure, compact, fatigue resistant, affordable
– MW scale development vision
• Based on kW development
• Scale-up issues
• Transition from experimental to demonstration stage
Page 5 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
S-CO2 Integrated System Testing
Bechtel Marine Propulsion Corporation Knolls Atomic Power Laboratory Schenectady, NY Bettis Atomic Power Laboratory West Mifflin, PA
Page 6 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
IST Physical Layout
Turbo-Generator
Recuperator
Precooler
Turbo-Compressor (not visible)
Page 7 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
IST Turbomachinery Turbo-Generator
Turbo-Compressor
Compressor/Diffuser Turbine
Thrust Bearing
Page 8 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Maximum Power Operation November 2013 – 40kWe
**40 kW on power analyzer
Page 9 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
-10
0
10
20
30
40
50
500 1000 1500 2000 2500 3000 3500 4000
Po
we
r (k
W) o
r Ef
fie
cie
ncy
(%)
Time (seconds)
TG Power
TC Power
Brayton Power
Brayton Efficiency
System Up-Power
35000
40000
45000
50000
55000
60000
500 1000 1500 2000 2500 3000 3500 4000
Spe
ed
(rp
m)
Time (seconds)
TC Speed
Page 10 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Compressor Map
Model Prediction for Design Operating Conditions
Test Data
Page 11 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
• Initial Conditions: Hot Idle (540°F/37,500 rpm) • TG speed increased • TC speed increased in steps • Compressor recirculation valve decreased in steps • Water flow automatically controlled to maintain compressor inlet T
Turbine-Generator Speed Turbine-Compressor Speed Recirculation Valve Position
Power Increase Transient
Page 12 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Intermediate Hx Recuperator Precooler
Power Increase Transient: Heat Exchanger Heat Duties
Page 13 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
IHX Heat Transfer
0
100
200
300
400
500
600
0 100 200 300 400 500 600
Me
asu
red
He
at
Tra
nsf
er
(kW
)
Predicted Heat Transfer (kW)
HTRI w/REFPROP
HTRI w/VMGThermo
Dittus-Boelter
Measured = Predicted
Page 14 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Precooler Heat Transfer
Page 15 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Page 16 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
IST with Recompression Cycle Control Features
This loop design shows how recompression control features could be placed in the IST, allowing loop hydraulic control for startup, heatup and low power operation.
Baseline recompressor recirculation
Page 17 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
IST Up-Power Maneuver in Recompression Configuration Using end states that have been optimized for adequate surge margin this up-power transient shows good performance, with minimal under/over shoot.
Up-power rates >1%/s would be possible for a well designed recompression loop.
Page 18 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
S-CO2 Heat Exchanger Development
Bechtel Marine Propulsion Corporation Knolls Atomic Power Laboratory Schenectady, NY Bettis Atomic Power Laboratory West Mifflin, PA
Page 19 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Heat Exchanger Testing
Heat Exchanger 1
CO2 PUMP
Heat Exchanger 2
1.5” Tubing with Swagelok fittings
½ or less Tubing with Swagelok fittings
2” to 10” sched 160 Pipe (316 SS)
DP3 2468 psig
T1 Recuperator vessel
DP1
Water heat Source 1
vent
HP-8
P1
HP-9
DP 2
T4
T3
ANSI Flange
Grayloc Flange
1” Tubing with Swagelok fittings
Water heat Source 2
(2) 10x2 Reducer
HP-2
Temp Conn 1
T2
River Water Cooling
(2) 3” graylocx to 2 “ Swagelok adapter
Flow-Meter
(2) Instrumentation Ports
2” Tubing with Swagelok fittings
2” graylocx to 1.5 “ Swagelok adapter
2” graylocx to 1.5 “ Swagelok adapter
Testing Conditions: Heat Input/Rejection 20-90 kWt
Pressure: ≈1,200-1,500 psi Temperature: ≈300-500°F Flow rate: ≈2-3 lbm/second
Page 20 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Recuperator Designs Tested
β=7,000-8,000 m2/m3 β=3,300-4,500 m2/m3
Page 21 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Folded Wavy-Fin Results
50
100
150
200
250
300
350
50 100 150 200 250 300 350
Heat Trnasfer Rate(kW)
Maximum Possible Heat Transfer Rate (kW)
Measured Thermal Performance
1.0 < ṁ <= 1.3
1.3 < ṁ <= 1.7
1.7 < ṁ <= 2.2
2.2 < ṁ <= 2.7
Design Point
ε = 1.0
ε = 0.9
ε = 0.8
(ṁ - lbm/sec)0
1
2
3
4
5
6
7
8
0 0.5 1 1.5 2 2.5 3
Pressure Drop(psid)
Mass Flow Rate (lbm/second)
Measured Hydraulic PerformanceHigh Pressure Side
1.0 < ṁ <= 1.3
1.3 < ṁ <= 1.7
1.7 < ṁ <= 2.2
2.2 < ṁ <= 2.7
Design Point
(ṁ- lbm/sec)
0
1
2
3
4
5
6
7
8
0 0.5 1 1.5 2 2.5 3
Pressure Drop(psid)
Mass Flow Rate (lbm/second)
Measured Hydraulic PerformanceLow Pressure Side
1.0 < ṁ <= 1.3
1.3 < ṁ <= 1.7
1.7 < ṁ <= 2.2
2.2 < ṁ <= 2.7
Design Point
(ṁ - lbm/sec)
Prototype demonstrated thermal-hydraulic performance.
Page 22 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Summary of Progress to Date
Bechtel Marine Propulsion Corporation Knolls Atomic Power Laboratory Schenectady, NY Bettis Atomic Power Laboratory West Mifflin, PA
Page 23 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
S-CO2 Integrated System Testing
• IST demonstrating controllability of a two shaft simple S-CO2 Brayton cycle
• Normal power operation over range of power levels up to ~50 kWe has commenced
• TRACE transient modeling:
– Validation has commenced
– Approaching real time execution
– Demonstrates controllability of re-compression cycle
Page 24 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
S-CO2 Heat Exchanger
Development
• IST heat exchangers meeting expectations and validating performance models
• More compact/fatigue resistant heat exchangers being designed, fabricated and tested in dedicated 300kW test facility
Page 25 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
MW Scale Development
Bechtel Marine Propulsion Corporation Knolls Atomic Power Laboratory Schenectady, NY Bettis Atomic Power Laboratory West Mifflin, PA
Page 26 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
S-CO2 Power Cycle Development Approach
Fundamental Testing Small Scale System and Component Tests
Large Component Development
Validated Design
Tools
Sandia Closed
Brayton Loops
HX Development & Test
CAPSTONE UNIT
HEATER SECTION
CHILLER SECTION EXPANSION JOINTS
CAPSTONE CONTOLLER
Small System
Test
Large Scale System Test
Plant Concept
Development
Component and System Modeling Development
Power Plant Concept
Development
Concept Development
Operational Test
Corrosion in 825F S-CO2 at 2800 psig
0
0.1
0.2
0.3
0.4
0.5
T-91
410S
S s
hot pee
ned
410S
S
Titaniu
m
Fe52
/ Ni4
8
316S
S s
hot pee
ned
17-7
PH
316S
S
Ni2
00 s
hot p
eene
d
304S
S
304S
S s
hot pee
ned
Allo
y 69
0
Allo
y 60
0
Ni2
00
Ap
pro
xim
ate
Ox
ide
Th
ick
ne
ss
(m
ils
)
1000-1700 hours
500-1000 hours
0-500 hours
Turbomachinery
Performance
Heat Exchanger
Performance
Integrated System Test
Technology Assessment
Fluid Behavior
Safety Implications
Material Behavior
Page 27 Supercritical CO2 Power Cycles Symposium September 9-10, 2014
Component Development
Turbomachinery Thermal Coatings Internal cooling
Path to S-CO2 Power Cycle Commercial Implementation Te
chn
olo
gy
Dev
elo
pm
ent
Bearings & Seals
Controls
Engineering Design - Analysis Codes - Component Specifications
Heat Exchangers Chemistry Control
Time
STEP Pilot Plant
~10 MWe FY16
Current
Pre-Commercial
Demo ~30-50 MWe
FY20
BMPC
SNL
Echogen
SunShot
Test loop component development - heater
Applications: Oxy-Fuel /Clean Coal
Concentrated Solar Power High Temperature Nuclear
Geothermal energy Navy Nuclear Propulsion
FY?? Applications: Waste Heat
Industry FY??
Materials Development
MW scale
kW scale
GE